Today at Atelier Kaz - ex-Honda R&D, F1, Indy/CART engineer

Started to service the brake callipers.
Despite the low mileage, certain part of the lower section of the car were covered in heavy rust.

Typical for UK based garaged NSX as it seems that it creates lots of condensation followed by the corrosion around the non-aluminium parts.
Couldn’t even move the parking brake holder pin so had to soak them in the acetone/ATF mixture overnight as well as where the parking brake cable is held inside the L shaped bracket.




While preparing for the compression check, I noticed that almost all of the bolts and nuts at the rear IG coil cover were very loose.
Also, one of the metal spacer was missing at the rear IG coil cover as well.
Nice shiny spacers that were installed properly. Later, I found the missing spacer together with the dropped valve cover meta/rubber seal trapped inside the narrow space around the sway bar holder. Seems like they were left there for ages based on the amount of corrosion.




Still very healthy IG coils with good seal at the tube and the spring is still bouncy.
#1 IG coil showed rust started to chew inside but nothing serious.




Proper OBD2 spec spark plugs but most of them were covered in oil at the insulator body and upper side of the threaded body especially the one at #4cyl so plug hole seals were installed without cleaning the surface properly and spark plug torque spec was not followed.






As the engine was running so smooth with very stable idle rpm and intake manifold pressure that I thought it’s going to be an easy routine task.


However, after what I found and discussed it with the owner, we decided to open the valve covers.
Again, no sign of liquid gasket applied whatsoever at the specified area of the valve cover gaskets so looks like the previous major service was carried out with not much attention to the detail.


There was no plan to touch the engine during this service so very limited parts stocked at my place and Honda Japan is closed until 17th so not much I can do on this occasion.
After lots of measurement and inspection, I think I have some idea on what’s happening so going to discuss the future plan with the owner and moving onto the brake side….



More delays…..



Joy of working on the classic cars…..

It’s more like creating images of 3D models inside your head than simply servicing the machine…..



I just hope other owners in the queue for my services would kindly wait patiently as I can’t just ignore what I found on each NSX…..




Kaz